A production and construction process of ALC concrete composite wall panel

Abstract

The present invention relates to a production and construction process of an ALC concrete composite wall panel, which includes mold installation and leveling, applying mold release oil, steel cage binding, slow-drying agent application, mold assembly, ALC board positioning, pipe clamp installation, electromechanical pre-embedded positioning, pre-embedded wire pipe position slotting, ALC board hanging, gluing, steel cage hanging, steel bar binding, electromechanical pre-embedded installation, transverse reinforcement rod installation, acceptance, concrete pouring, demoulding, and water washing. The process of the present invention uses pipe clamps to anchor the ALC board to the steel cage, thereby firmly fixing the ALC board; upper and lower reinforcing ribs and corner reinforcing ribs are placed in the ALC wall panel concrete connecting belt to ensure that the connecting belt is not easy to crack, and the force on the top of the wall panel is concentrated on the cast-in-place concrete connecting belt to reduce the risk of cracking of the ALC board; the obtained product not only improves the product quality of the ALC concrete composite wall panel, but also improves the external appearance of the product, improves the competitiveness of the product, and has good economic benefits.

Description

Technical Field

[0001] The invention relates to a production and construction process of an ALC concrete composite wallboard, belonging to the technical field of building construction technology. Background Art

[0002] Autoclaved Lightweight Aerated Concrete Partition Board, referred to as ALC (Autoclaved Lightweight Concrete) board (lightweight partition board), its main components include cement, silica sand, gypsum, bubbling agent, lightweight aggregate, etc. These raw materials are mixed, cast with steel cage, and then steamed under high temperature and high pressure. ALC lightweight partition board is a new type of building material with wide application, which has the advantages of light weight, high strength, sound insulation, heat preservation, fire resistance, good earthquake resistance, etc., and has broad application prospects.

[0003] ALC panels have been widely used in prefabricated buildings in the prior art, but most of them are used as a separate prefabricated wall panel in partition walls. There are few studies on composite wall panels prefabricated with reinforced concrete because the quality problems caused by the existing production process are difficult to solve. For example, due to the large size and light weight of ALC panels, it is not easy to position and fix them during the concrete pouring process, and it is easy to be misplaced; during the pouring and vibrating process, the concrete material exerts pressure and compaction on the contact gap between the ALC panel and the mold, which makes it easy for the ALC panel and concrete joints to leak; at the concrete connection zone between two adjacent ALC panels, the connection zone is difficult to be smooth and flat due to the precipitation of moisture, and it is easy to crack, and the ALC panel is stressed and cracked due to the lack of stress on the connection zone. These problems are the problems that the standardized construction process of ALC concrete composite wall panels focuses on solving, and are also the top priority for improving the production and construction quality of ALC concrete composite wall panels. That is to say, the existing technical solution for ALC panels and concrete pouring is to place the ALC panels on the mold according to the design drawings and directly pour concrete together with the steel cage. The defects of this operation include: the ALC board is difficult to position, and its position is prone to shifting during the concrete pouring process. The concrete joints are prone to leakage onto the ALC board surface, causing pollution and affecting the appearance. The concrete connecting strips and ALC boards of the ALC boards are prone to cracking, and the ALC boards are not tightly fitted to the bottom surface of the formwork, which makes it easy for the gaps to squeeze and seep slurry, causing the contact surface between the ALC board and the formwork to be uneven and contaminated. Summary of the invention

[0004] 1. Technical issues to be resolved

[0005] In order to solve the above problems in the prior art, the present invention provides a production and construction process of an ALC concrete composite wall panel, by which a concrete MIC prefabricated component of an ALC lightweight partition panel is obtained.

[0006] (II) Technical solution

[0007] In order to achieve the above object, the main technical solutions adopted by the present invention include:

[0008] A production and construction process of an ALC concrete composite wall panel, wherein the ALC concrete composite wall panel comprises a concrete module beam, a concrete structural column, a concrete ring beam and an ALC panel embedded therein, and a concrete connecting strip is provided between two adjacent ALC panels. The production and construction process of the composite wall panel comprises the following steps:

[0009] S1. Install and level the concrete casting mold outside the ALC;

[0010] S2. Clean the inside of the mold and apply mold release oil;

[0011] S3. The steel cage should be tied to the size of the mold;

[0012] S4. Evenly apply slow-drying agent to the corresponding mold side panels where washing is required on the corresponding combined wall panels. The slow-drying agent should not cause dripping or contamination. After the application is completed, assemble the mold and fix the side panels.

[0013] S5. Mark the position where the ALC board is placed on the mold, and then print the outline of the ALC board to ensure the accurate position of the ALC board;

[0014] S6. Insert the pipe clamps used for ALC fixation into the ALC board at the required spacing, and mark the positions of the electromechanical pre-buried pipelines;

[0015] S7. According to the positioning mark line, grooves are cut on the ALC board, and mechanical and electrical pre-buried pipelines are chiseled out, and positions for the bottom box are reserved;

[0016] S8. Hang the ALC board according to the position of the mold mark, and it must not be placed crookedly or biased towards the positioning line;

[0017] S9. Apply glass glue evenly in the gap between the ALC board and the mold to prevent leakage onto the ALC board surface;

[0018] S10. Hang the steel cage between the gaps of the ALC plates and connect it with the pipe clamp anchors. Place reinforcement bars at the corners of the ALC plates and tie them together.

[0019] S11. Pre-embed the electromechanical and electrical conduits at the notch position of the ALC board;

[0020] S12. After the electromechanical pre-embedding is completed, install the transverse reinforcement rods on the side of the formwork. The transverse reinforcement rods are used to firmly press the ALC board on the formwork to prevent leakage at the bottom junction gap;

[0021] S13. After the above processes are completed, the molds, steel bars, wire ears, and electromechanical pre-embedded parts shall be fully inspected and accepted again in strict accordance with the drawings;

[0022] S14. After acceptance, concrete pouring operation shall be carried out. During the material discharge process, the molds contaminated shall be cleaned in time to keep the molds clean;

[0023] S15. After the concrete solidifies, remove the mold and transverse reinforcement rods, and then lift the product from the mold platform to the washing room for washing. After washing, lift it to the storage point for storage. The storage rack must be tightened to the product for safe storage.

[0024] In the production and construction process as described above, preferably, the ALC panels are provided with two or more panels, and a concrete connecting strip is provided between two adjacent ALC panels.

[0025] Furthermore, reinforcing ribs with a diameter of 5 to 15 mm are placed above and below the pipe clamps in the concrete connection strips of adjacent ALC panels, and reinforcing ribs with a 90° bend are provided at the corners of the ALC panels.

[0026] In the production and construction process as described above, preferably, the release oil is a concrete release agent, and the slow-drying agent is glycerol or propylene glycol.

[0027] In the production and construction process as described above, preferably, when grooving, the grooving width and depth are slightly larger than the actual size of the wire tube and the base box, and the ALC board must not be placed on the mold for grooving operations to avoid secondary contamination of the mold.

[0028] In the production and construction process as described above, preferably, the pipe clamp is an L-shaped steel pipe and a steel plate that are fixedly connected, the steel pipe is fixedly connected to the ALC plate; and the steel plate is bent and anchored into the steel skeleton.

[0029] Furthermore, the length of the steel pipe is 50-90 mm, the length of the steel plate is 130-180 mm, and each ALC plate is embedded with 12 pipe clamps, wherein each long side is embedded with 4 pipe clamps, and the distance between the pipe clamps is 900 mm; and each short side is embedded with 2 pipe clamps, and the distance between the pipe clamps is 300 mm.

[0030] In the production and construction process as described above, preferably, the glass glue is replaced by a caulking agent.

[0031] In the production and construction process as described above, preferably, the pouring operation requires compaction through vibration, and the surface is flat and smooth without quality defects such as honeycomb surface and bubbles.

[0032] In the production and construction process as described above, preferably, the water washing surface requires that the exposed depth of the stones should not be less than 4 mm.

[0033] (III) Beneficial effects

[0034] The beneficial effects of the present invention are:

[0035] The present invention provides an improved production and construction process of ALC concrete composite wall panels. The ALC panel outline is engraved on the mold to facilitate the placement and positioning of the ALC panel. The ALC panel is anchored and connected to the steel cage by a pipe clamp, so that the ALC panel is firmly fixed, ensuring the neatness of all ALC panels in the finished composite wall panel. The ALC panel is firmly pressed on the mold platform by designing a transverse reinforcement rod on the side of the mold platform. In addition, the gap between the ALC panel and the mold is sealed with glass glue, thereby isolating the leakage pollution of the outer wall of the ALC panel, ensuring the neatness of the wall surface and reducing the later repair work. Upper and lower reinforcing ribs and corner reinforcing ribs are placed in the concrete connecting belt of the ALC wall panel to ensure that the connecting belt is not easy to crack, and the force on the top of the wall panel is concentrated on the cast-in-place concrete connecting belt, reducing the risk of cracking of the ALC panel. These process improvements overcome the problems of easy deviation of the ALC panel in the prior art, poor appearance of the outer wall, and easy cracking of the concrete connecting belt and the ALC panel.

[0036] The present invention provides a production and construction process for an ALC concrete composite wall panel. The prepared product not only improves the product quality of the ALC concrete composite wall panel, but also improves the external appearance of the product, improves the competitiveness of the product, achieves cost reduction and efficiency improvement in production, and has good economic benefits.

[0037] The production and construction process provided by the present invention provides guidance for the subsequent production of similar products, effectively reduces the repair work in the back field, helps to reduce labor costs, shortens the production cycle, and provides a good direction for reducing the cost of prefabricated buildings. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 This is the structural diagram of the ALC concrete composite wall panel;

[0039] Figure 2 The construction process of ALC concrete composite wall panels;

[0040] Figure 3 This is a construction diagram for mold installation and leveling;

[0041] Figure 4 Schematic diagram of mold cleaning and mold release oil application;

[0042] Figure 5 This is a construction diagram for steel cage bundling;

[0043] Figure 6 This is a construction diagram for applying slow-drying agent and assembling the mold;

[0044] Figure 7 Construction diagram for positioning the ALC board;

[0045] Figure 8 This is the construction diagram for the installation of ALC board and pipe clamps;

[0046] Fig. 9 This is a schematic diagram of the slotting for the electromechanical pre-buried wire conduit of the ALC board;

[0047] Fig.10 This is a schematic diagram of the ALC panel hanging installation;

[0048] Fig.11 This is a construction diagram of the steel cage hoisting and tying connection;

[0049] Fig.12 This is the construction diagram for pre-buried mechanical and electrical installation;

[0050] Fig.13 A construction diagram for inspection and acceptance before cutting;

[0051] Fig.14 This is a construction diagram for concrete pouring;

[0052] Fig.15 This is a construction diagram for storage after washing;

[0053] Fig.16 This is a physical diagram of the pipe clamp;

[0054] Fig.17 This is an example of pipe clamp and steel cage anchoring;

[0055] Fig.18 For die engraving examples;

[0056] Fig.19 This is an example of a transverse reinforcement rod;

[0057] Fig. 20 An example of rib placement;

[0058] Fig.21 Example of caulking the gap;

[0059] Fig. 22 This is an overall example of the finished product;

[0060] Fig.23 This is a partial example of the finished product.

[0061] [Description of Reference Numerals]

[0062] 1: Concrete module beam;

[0063] 2: Concrete structural column;

[0064] 3: Concrete ring beam;

[0065] 4: Concrete connecting belt;

[0066] 5: ALC board. DETAILED DESCRIPTION

[0067] In order to better explain the present invention and facilitate understanding, the present invention is described in detail below through specific implementation modes in conjunction with the accompanying drawings.

[0068] Example 1

[0069] The concrete MIC prefabricated components using ALC lightweight partition boards are shown in the structural diagram. Figure 1 As shown, it is integrally cast by concrete module beam 1, concrete structural column 2, concrete ring beam 3, concrete connecting belt 4 and ALC board 5. The concrete module beam 1, concrete structural column 2 and concrete ring beam 3 surround the periphery of ALC board 5, and the concrete connecting belt 4 is between two adjacent ALC boards 5. The prefabricated component is prepared by the production and construction process of improved ALC concrete composite wall panel. The schematic diagram of the process is shown in Figure 2 As shown, the specific steps include:

[0070] (1) Mold installation and leveling. Figure 3 As shown in the figure, after the mold arrives at the site, the size and flatness of the base of the mold are reviewed. After verification, the mold is fixed and leveled to ensure its flatness.

[0071] (2) Apply mold release oil to the mold. Figure 4 As shown, after the mold is installed and leveled, the mold is cleaned again and the mold release oil is applied. The mold release oil is a concrete release agent. The mold must be thoroughly cleaned before painting, and no dust or other dirt should be present. The mold release oil should be applied fully.

[0072] (3) Tie up the steel cage. Figure 5 As shown, while the mold is being processed, the steel cage is being tied. The steel bar tying is strictly constructed according to the drawing, and the steel bar specifications, spacing, and row spacing are accurate.

[0073] (4) Apply slow-drying agent and assemble the mold. Figure 6 As shown, where the components need to be washed, apply slow-drying agent to the corresponding mold side plate. The slow-drying agent can be glycerol or propylene glycol. The slow-drying agent is required to be applied evenly without dripping or contamination. After the application is completed, the mold is assembled and the side plate is fixed.

[0074] (5) ALC board positioning. Figure 7 As shown in the drawing, mark the position where the ALC board will be placed on the mold to ensure the accuracy of the ALC board position. Construction is carried out according to the drawing. In this step, the mold is engraved to engrave the ALC board outline positioning line to facilitate the positioning of the ALC board.

[0075] (6) ALC board and pipe clamp installation, electromechanical pre-embedded positioning. Figure 8 As shown, embed the ALC fixed pipe clamps into the ALC board at the required spacing, and mark the positions of the electromechanical pre-buried pipelines according to the drawings.

[0076] (7) Slotting of the electromechanical pre-buried wire conduit of the ALC board. Fig. 9 As shown, according to the positioning mark line, grooves are cut on the ALC board to chisel out the wire tube and reserve space for the bottom box. The groove width and depth should be slightly larger than the actual size of the wire tube and bottom box. The ALC board must not be placed on the mold for groove cutting to avoid secondary contamination of the mold.

[0077] (8) ALC board hanging. Fig.10 As shown, hang the ALC board according to the position marked on the mold and place it strictly according to the position on the drawing. It must not be skewed or deviated from the positioning line. Perform acceptance inspection 1 first. If it is skewed or deviated from the positioning line, make adjustments in time.

[0078] (9) Gluing: Apply glass glue evenly in the gap between the ALC board and the mold to prevent leakage onto the ALC board surface.

[0079] (10) Lifting of steel cage and tying of steel bars. Fig.11 As shown, after the inspection of the steel cage is completed, place the steel cage between the gaps of the ALC board according to the drawing, place reinforcing bars at the concrete connecting strip and the corners of the ALC board, and tie them together. Bend and anchor the ALC pipe clamp into the steel skeleton. The temporary lifting ring needs to be anchored to the steel cage on the mold. After the steel cage is tied, adjust the steel spacing, protective layer pads, etc.

[0080] (11) Pre-buried installation of electromechanical equipment. Fig.12 As shown in the figure, after the steel bars are tied, the electromechanical and electrical conduits are pre-buried according to the slot positions of the ALC plates. For the cast-in-place part, the conduits must be firmly tied to the steel skeleton after the conduits are accurately positioned to avoid displacement of the conduits due to subsequent construction.

[0081] (12) Installation of transverse reinforcement rods. After the electromechanical pre-embedding is completed, install transverse reinforcement rods on the side of the formwork to firmly press the ALC board on the formwork to prevent leakage at the bottom junction gap.

[0082] (13) Inspection before cutting 2. Fig.13 As shown, after all the processes are completed, the molds, steel bars, wire ears, electromechanical embedding, etc. are once again comprehensively inspected and accepted in strict accordance with the drawings.

[0083] (14) Concrete pouring and polishing. Fig.14 As shown, after acceptance, concrete pouring and dropping operations are carried out. The concrete must be vibrated and compacted, with a smooth and flat surface. Quality defects such as honeycomb, bubbles, etc. are not allowed. During the discharge process, the mold contaminated should be cleaned in time to keep the mold clean.

[0084] (15) Formwork lifting, washing, acceptance inspection 3. Storage. After the concrete solidifies, remove the mold and lift the product from the formwork platform to the washing room for washing. The exposed depth of the gravel on the washing surface must not be less than 4mm. After washing, lift it to the storage point for storage. The storage rack and the product must be fastened and stored safely. Fig.15 As shown, the generation is now complete.

[0085] Example 2

[0086] This embodiment provides the production of prefabricated components for concrete MiC interior partition walls in classrooms, wherein 7 ALC panels are used, concrete structural columns, concrete module beams, concrete ring beams are used to wrap the ALC panels, concrete connecting strips are used to wrap and separate the ALC panels, and the composite wall panels are used for the interior partition walls of concrete MiC in classrooms. The specific production and construction process is based on the embodiment 1, specifically,

[0087] 1. Engrave the corner outlines of 7 ALC boards on the mold to facilitate the placement and positioning of the ALC boards, such as Fig.18 shown.

[0088] 2. The positioned ALC panels are connected to the cast-in-place concrete of the structural columns, module beams, and ring beams through the ALC fixed pipe clamps. The fixed pipe clamps are L-shaped steel pipes and steel plates that are fixedly connected, such as Fig. 20 As shown in the figure, the steel pipe at one end of the pipe clamp is embedded in the ALC board (embedded length 65mm), and the steel plate at the other end is anchored in the steel skeleton (anchored length 150mm). Each ALC board is embedded with 12 pipe clamps, of which 4 pipe clamps are embedded in each long side, with a pipe clamp spacing of 900mm; and 2 pipe clamps are embedded in each short side, with a pipe clamp spacing of 300mm.

[0089] 3. Apply glass glue evenly to seal the gap between the ALC board and concrete at the bottom and the mold gap to isolate leakage pollution. Fig.21 shown.

[0090] 4. Place 10mm diameter reinforcement bars above and below the pipe clamps in the concrete connection strips of adjacent ALC panels, and place 90° bent reinforcement bars at the corners of the ALC panels.

[0091] 5. Design a transverse reinforcement rod on the side of the mold platform to firmly press the ALC board on the mold platform to avoid leakage at the bottom junction gap. The finished product is as follows Fig. 22 and Fig.23 shown.

[0092] The improved process provided by the present invention not only improves the product quality of ALC concrete composite wall panels, but also improves the external appearance of the products, enhances the competitiveness of the products, reduces production costs and increases efficiency, and has good economic benefits; it also provides guidance for the production of subsequent similar products, effectively reduces the back-end repair work, helps to reduce labor costs, shortens the production cycle, and provides a good direction for reducing the cost of prefabricated buildings.

[0093] The above is only a preferred embodiment of the present invention, and does not limit the present invention in other forms. Any person skilled in the art can use the above disclosed technical content to change or modify it into an equivalent embodiment with equivalent changes. However, any simple modification, equivalent change and modification made to the above embodiment according to the technical essence of the present invention without departing from the technical solution of the present invention still belongs to the protection scope of the technical solution of the present invention.

Claims

1. A production and construction process of ALC concrete composite wall panels, wherein: The ALC concrete composite wall panel includes a concrete module beam, a concrete structural column, a concrete ring beam and an ALC board embedded therein, and a concrete connecting strip is provided between two adjacent ALC boards. The production and construction process of the composite wall panel includes the following steps: S1. Install and level the concrete casting mold outside the ALC; S2. Clean the inside of the mold and apply mold release oil; S3. The steel cage should be tied to the size of the mold; S4. Evenly apply slow-drying agent to the corresponding mold side panels where washing is required on the corresponding combined wall panels. The slow-drying agent should not cause dripping or contamination. After the application is completed, assemble the mold and fix the side panels. S5. Mark the position where the ALC board is placed on the mold, and then print the outline of the ALC board to ensure the accurate position of the ALC board; S6. Insert the pipe clamps used for ALC fixation into the ALC board at the required spacing, and mark the positions of the electromechanical pre-buried pipelines; S7. According to the positioning mark line, grooves are cut on the ALC board, and mechanical and electrical pre-buried pipelines are chiseled out, and positions for the bottom box are reserved; S8. Hang the ALC board according to the position of the mold mark, and it must not be placed crookedly or biased towards the positioning line; S9. Apply glass glue evenly in the gap between the ALC board and the mold to prevent leakage onto the ALC board surface; S10. Hang the steel cage between the gaps of the ALC plates and connect it with the pipe clamp anchors. Place reinforcing bars at the corners of the ALC plates and tie them together. S11. Pre-embed the electromechanical and electrical conduits at the notch position of the ALC board; S12. After the electromechanical pre-embedding is completed, install the transverse reinforcement rods on the side of the formwork. The transverse reinforcement rods are used to firmly press the ALC board on the formwork to prevent leakage at the bottom junction gap; S13. After the above processes are completed, the molds, steel bars, wire ears, and electromechanical pre-embedded parts shall be fully inspected and accepted again in strict accordance with the drawings; S14. After acceptance, concrete pouring operation shall be carried out. During the material discharge process, the molds contaminated shall be cleaned in time to keep the molds clean; S15. After the concrete solidifies, remove the mold and transverse reinforcement rods, and then lift the product from the mold platform to the washing room for washing. After washing, lift it to the storage point for storage. The storage rack must be tightened to the product for safe storage.

2. The production and construction process according to claim 1, characterized in that: The ALC panels are provided with two or more pieces, and a concrete connecting strip is provided between two adjacent ALC panels.

3. The production and construction process according to claim 2, characterized in that: In the concrete connection zone of adjacent ALC panels, reinforcing ribs with a diameter of 5 to 15 mm are placed above and below the pipe clamps, and reinforcing ribs with a 90° bend are provided at the corners of the ALC panels.

4. The production and construction process according to claim 1, characterized in that: The demoulding oil is a concrete demoulding agent, and the slow-drying agent is glycerol or propylene glycol.

5. The production and construction process according to claim 1, characterized in that: When grooving, the groove width and depth should be slightly larger than the actual size of the wire tube and base box. The ALC board must not be placed on the mold for grooving operations to avoid secondary contamination of the mold.

6. The production and construction process according to claim 1, characterized in that: The pipe clamp is an L-shaped steel pipe and a steel plate that are fixedly connected. The steel pipe is fixedly connected to the ALC plate; the steel plate is bent and anchored into the steel frame.

7. The production and construction process according to claim 6, characterized in that: The length of the steel pipe is 50-90 mm, the length of the steel plate is 130-180 mm, and each ALC plate is embedded with 12 pipe clamps, wherein each long side is embedded with 4 pipe clamps, and the distance between the pipe clamps is 900 mm; each short side is embedded with 2 pipe clamps, and the distance between the pipe clamps is 300 mm.

8. The production and construction process according to claim 1, characterized in that: The glass glue is replaced by a caulking agent.

9. The production and construction process according to claim 1, characterized in that: The pouring operation requires compaction through vibration, a smooth and flat surface, and no quality defects such as honeycombs and bubbles should occur.

10. The production and construction process according to claim 1, characterized in that: The water washing surface requires that the exposed depth of the stones shall not be less than 4mm.

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